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Old 06-15-2011, 02:42 PM   #1
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Question onan generator issue

Hi,
The Onan 7.5 quiet diesel (HDKAJ spec D) in our new to us '99 Adventurer threw a magnet on the rotor. I know from lurking that that's not a new problem on the forums - just a new problem for us!

So - DH is rebuilding the generator. We bought and replaced the rotor and stator assembly, and he is now troubleshooting, since it still won't start...just clicks twice.

He took the starter off and tested it at a friend's car repair shop across the road - it's fine. He started the motorhome to make sure the battery power was up, cleaned battery connections - still nothing.

The generator only has 340 hours on it.

Any suggestions?
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Old 06-15-2011, 02:47 PM   #2
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Quote:
Originally Posted by winniehaha View Post
Hi,
The Onan 7.5 quiet diesel (HDKAJ spec D) in our new to us '99 Adventurer threw a magnet on the rotor. I know from lurking that that's not a new problem on the forums - just a new problem for us!

So - DH is rebuilding the generator. We bought and replaced the rotor and stator assembly, and he is now troubleshooting, since it still won't start...just clicks twice.

He took the starter off and tested it at a friend's car repair shop across the road - it's fine. He started the motorhome to make sure the battery power was up, cleaned battery connections - still nothing.

The generator only has 340 hours on it.

Any suggestions?
1st off my condolances for such bad luck.... a thrown magnet @ 340 hours is almost tragic. Onan 7.5 diesel units for the most part are bullet proof and in most cases idiot proof! (2,450 hours on my 20 year old unit and only 1 broke fuel pump and ALOT of care and maintenance)

To clarify.... your engine that used to work fine now won't start after you pulled the generator portion off?
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Old 06-15-2011, 03:36 PM   #3
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Does the starter turn over? If not, check the fuses. Normally under the panel where the start switch is located.
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Old 06-15-2011, 03:41 PM   #4
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Hi,
Thanks for the reply.
We bought the rig about 6 weeks ago. The previous owner started it to show that it worked, while we were looking through it. Started right up, purred along - worked fine. Then, a couple of days after we bought it, we started it and ran it for a while, and, again, it was fine.

So - we were at a music festival about a week ago, and needed the generator...tried to start it, and not only would it not start - coughed, etc., but threw a magnet. Messed up the stator assembly - bits of magnet everywhere.

We bought a new rotor and stator from the nearest Cummins/Onan place. DH has put the new parts on, but generator won't start. Starter checks out fine, batteries are up, connections clean. Starter engages, but won't spin up the flywheel.

He primed the system, but still no soap.

He's wondering if the batteries just don't have enough amperage, even though they show that they're charged up.

Could use advice.

Thanks
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Old 06-15-2011, 04:01 PM   #5
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It should at least turn over. Do you have a way of tying the MH, Chassis batteries to the house batteries if so that should give you enough power to turn it over.

Also try turning the genset motor with a wrench to make sure it is not frozen from some type damage incurred when the magnet was thrown. Be sure to take proper precautions such as kill switch on, etc before manually turning.
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Old 06-15-2011, 04:01 PM   #6
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[QUOTE=winniehaha;879991]Hi,
Thanks for the reply.
We bought the rig about 6 weeks ago. The previous owner started it to show that it worked, while we were looking through it. Started right up, purred along - worked fine. Then, a couple of days after we bought it, we started it and ran it for a while, and, again, it was fine.

So - we were at a music festival about a week ago, and needed the generator...tried to start it, and not only would it not start - coughed, etc., but threw a magnet. Messed up the stator assembly - bits of magnet everywhere.

We bought a new rotor and stator from the nearest Cummins/Onan place. DH has put the new parts on, but generator won't start. Starter checks out fine, batteries are up, connections clean. He primed the system, but still no soap.

Hi Winnie, Ouch! thats very unusual but, It Happens! sounds like something is binding....or a bolt that is too long and tightens against the diesel.if it ran before repairs... and batteries ,starter all check out then....its time to back track and see if you can find the problem. any one have an amp draw meter...check the amps when starter engages ...Can DH turn motor over by hand? some where to start...some one will be help more than this just keep smiling
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Old 06-15-2011, 04:09 PM   #7
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Hi,

He says it will turn by hand. Doesn't seem to be binding - he says he can tell there is compression.
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Old 06-15-2011, 04:16 PM   #8
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Quote:
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Hi,

He says it will turn by hand. Doesn't seem to be binding - he says he can tell there is compression.
If the starter engages and you can turn by hand it has to be low voltage at the starter.batterys need a boost or charge...check voltage at the starter when engaged bet its low...also amps
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Old 06-15-2011, 04:25 PM   #9
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Thanks - that's kind of what he thought it might be...still working on it...I'll be away from the computer, but will post progress tomorrow.
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Old 06-15-2011, 05:12 PM   #10
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Well, that was it! Not enough power to turn it over.

He hooked up the truck batteries (Dodge 3500) to the generator, and it started. Whew! After the price of the parts (yikes!), I was sure hoping he didn't get himself in over his head, and we'd have to take it to the Cummins/Onan place after all...

So, now, beef up the batteries for the genset.

Thanks to all who replied.
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Old 06-15-2011, 08:16 PM   #11
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What music festival ?

How old are the batteries?
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